Storm door unit



Nov. 23, 1954 L. J. MILONE 2,695,084

STORM DOOR UNIT Filed Feb. 5, 1949 I 2 Sheets-Sheet l INVENTOR.

BY M: id clfl 7 /Mv Nov. 23, 1954 J. MILONE STORM DOOR UNIT 2 Sheets-Sheet 2 Filed Feb. 3, 1949 35a, Fe

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5 A W 0 5 mx 4 h 4 K Q 6/ {a 3 5 4 United States Pate sroaM noon UNIT Louis J. Milone, Livingston, N J., assiguorto TheaEagle- Pic-her Company, Cincinnati, Ohio, a corporation of Ohio Application February 3, 1949, Serial No. 74,357

Claims. (6!. 18936) This invention relates to convertible storm door units adapted particularly for residential buildings to provide protection against excessive heat loss during winter seasons and adapted to be used as screen doors during the summer.

The invention contemplates va complete prefabricated metal unit including a frame, a door, and convertible panels containing glass and screen wire respectively to accommodate winter and summer conditions. The frame of the structure is adapted for permanent installation in a door openin of a building just outside the standard door and the oor of the convertible unit is hung upon this permanently installed frame. The invention is directed particularly to an improved corner joint for a storm door consisting of hollow framing members, the framing members being permanently joined at the corners by inserts which reside within the adjoining ends of the hollow framing members.

The primary objects are to provide a corner insert arranged to be slipped telescopically into the end portions of the hollow framing members for rapid and convenient assembly of the door structure; to provide a corner in sert and cooperating wedge members which establish a rigid wedging engagement with the hollow framing members as an incident to the operation of slipping the parts together; and to provide a structure in which .the insert and wedge members reside entirely within the hollow framing members upon assembly.

Metal doors, even of the type built from lightweight aluminum, or hollow sheet material, are apt to be of substantial weight, but they must also be very durable since the door is opened and closed frequently and is jarred or strained to some degree in doing so each time. In the present structure, hollow channel-like lengths of material are employed to constitute the vertical and crosswise portions of the door, and the rigidity which is requisite to enable an assembly of these channels'satisfactorily to withstand the most severe usage is accomplished by the provision of the improved corner or joint structure which is convenient to assemble. Although convertible storm door units made of wood have been 4 offered in the past, their installation required the services of a carpenter and although they are lower, in factory price, than metal units, the simplicity of the door assembly of the present invention enables the whole unit, installed, to compare favorably with the cost of a Wooden structure and, of course. the metal is substantially more durable and weather resistant.

Briefly, the improved door unit is constructed in a simple manner from a basic hollow metal framing extrusion, such as aluminum, cut to length and joined together by corner inserts telescopically engaged, and wed ed within the adiacent ends of the hollow framing members. The extruded members have .an internal marginal flange for mounting the glass andscreen panels and a pair of external spaced fins providing .a recess for nesting the hinges and latch flush plates in flush relationship with the edges of the doors. The door unit is of exceptional simplicity and strength and the various door sizes may be produced and assembled at low cost simply by cutting the extruded sections to length to form vertical and cross framing members, slipping them into wedging' engagement upon the corner inserts' and clinching the 'members into permanent union with the=inserts.'

Other details andfeatures'of'the invention are disclosed in the drawings and in thefollowing detailed d e 2,695,084 Patented Nov. 23, l 954 scription disclosing a preferred embodiment of the invention.

In the drawings:

Figure l is a general view illustrating the combined storm and screen door structure as installed in a door opening with the glass and screen panels mounted therein for storm doorusage.

Figure 2 is an enlarged fragmentary view, partially in section, illustrating one of the corner joints of the door.

Figure 3 is a sectional view taken on line 3-3, Figure 2, further detailing the corner structure.

Figure 4 is a sectional View taken on line 44, Figure 2.

Figure 5 is a diagrammatic view illustrating a vertical side member and corner insert prior to assembly.

Figure 6 is a diagrammatic view similar to Figure 5, showing the vertical member and corner insert in assembled relationship prior to the insertion of the horizontal member.

Figure 7 is a sectional view taken on line 7-7, Figure 6, illustrating the wedging action of the corner insert relative to the frame members during final assembly.

Figure 8 is an enlarged diagrammatic view illustrating the wedging action as the horizontal frame member is initially slipped upon the corner insert and into engagement with the diverging wedge plates to force the plates toward one another.

Referring to Figure l, the storm door, indicated generally at 20, is mounted within a door opening having a conventional wood door frame or casing 21. A secondary metal door frame or buck 22, formed from angle shaped framing strips, is installed within the wood door frame to delineate accurately the opening for the storm door. The secondary metal frame adjustably embraces the corners of the door frame 21, each strip being provided with a face plate or flange 23 seated upon the outer surface of the door frame 21 and having a right angular flange forming the door receiving frame or case. The framing strips are secured by means of wood screws 25 passing through the face plate 23 into the wood frame 21. By this arrangement the secondary metal door frame 22 maybe adjusted with reference to the wood frame to provide a square, accurately sized opening or casing to receive the storm door.

The storm'door frame structure 20 is formed from vertical stiles or framing members and horizontal framing members 36 and 37 at the top and bottom re spectively. These framing members are formed from aluminum or aluminum alloy extrusions and are of duplicateshape in cross section. Each constitutes generally a hollow rectangular body 38, provided with a web or flange 39 located centrally along the inner surface and a pair of parallel fins or flanges 40-40 extending outwardly as a continuation of the body walls.

As shown in Figure 1, the lower framing member 37 is Wider than the top and side members. This member is a duplicate of the side and top members with the exception of the flanges 40-40 which extend downwardly a substantial distance beyond the body of the member to increase the width dimension and provide the desired appearance.

The vertical and horizontal framing members are joined together at the four corners by means of a reinforcing insert or grid member 44 (Figure 2). This member constitutes a casting or forging providing a pair of limbs 45 and 46 disposed at right angles to each other. The limb 45 is adapted to be telescopically inserted in the horizontal framing members 36 and 37 and the limb 46 into the vertical framing member or stiles 35. To provide maximum strength consistent with light weight construction, each limb is flanged marginally as at 47 and is pro vided also with a series of intermediate ribs 48.

In order to permit the corner insert to be slipped into the ends of the vertical stiles 35, the inner wall 351: of each vertical stile is slotted longitudinally as at 49 at opposite ends (Figure 3). The opposite side edges of the slot are delineated by the curved flanges indicated at dim-4% which form a part of the inner wall 35a. The corner insert 44 includes a neck portion'fiti of reduced Width intermediate the limbs 45 and 46, and as shown in Figures 2 and -8, the marginal flange 47, which delineates the neck 50, is further provided on opposite sides with notches 49b--49b. As the limb 46 of the insert is slipped into the end of the vertical stile 35, the notches 49b provide clearance for the curved flanges 490, the flanges residing loosely within the notches (Figure 8).

It will be noted in Figure 8, that the neck portion 50 delineates a pair of shoulders 51 and 52 at its opposite ends. Upon insertion of the grid into the vertical stile, the shoulders 52 rest against the internal surface of the end wall 35a at the two corners of the stile adjacent the curved flanges 49a. After being inserted, as shown in Figure 6, the corner insert is wedged rigidly in position in the end of the vertical stile by a pair of wedge plates 53-53 which are placed on opposite sides of the neck portion 50, the wedge plates having their inner ends seated against the shoulders 51.

As best shown in Figure 8, the outer ends of the wedge plates are beveled as at 53a to provide a wedging action against the corners and inner wall 35a of the vertical stile. The plates 53 have a length to provide a force fit when forced to a parallel position between the shoulders 51 and the wall surface 35a of the vertical stile. The length of the wedge plates causes them to diverge outwardly with respect to one another when they are placed in position as shown in Figure 8, with their beveled ends 53a resting against the corners of the stile. When the open end of the horizontal stile 36 is slipped upon the limb 45 of the insert, with the wedge plates in position upon it, the diverging wedge plates are forced toward one another by engagement of the side walls of the horizontal stile, as indicated by the arrows in Figure 8. As the beveled ends 53a cam over the corners of the wall surface 3511, the wedge plates are forced toward the right against shoulder 51, as viewed in Figure 8, to take up any initial looseness which may exist between the vertical stile 35 and corner insert. The wedging force increases progressively as the ends of the wedge plates slide across the flat wall surface 35a toward straight condition (Figure 3), thus providing a toggle action which is effective to force the insert under high pressure toward the right to clamp the end wall 35a rigidly between the shoulders 52 and the bevelled ends of the wedge plates.

Upon reaching the final position shown in Figure 3, the wedge plates are forced into parallelism with the plane of the corner insert and the bevelled ends 53a of the plates nest across the curved flanges 49a. In this condition, the end of the horizontal stile 36 is in abutment with the surface of wall 35a of the vertical stile as shown in Figure 2. The flanges 49a are slightly yieldable and are compressed slightly toward one another during the final wedging engagement of the plates, such that the wedge plates frictionally engage and bind the horizontal framing member to the horizontal limb of the insert. It is to be noted, that in assembled condition, the curved flanges 49a project into the end of the horizontal framing member and that all of the component parts of the insert structure are concealed from view.

After the framing members are engaged upon the reinforcing grids, each corner assembly is permanently united by forming indentations 55 in the framing members in registry with notches 56 formed in the outer edges of the grid blocks. These dents may be formed by a machine such as an arbor press having a properly shaped forming tool, or by hand if desired. By this arrangement the respective corners of the frame are permanently clinched together and due to the wedged interfit of the parts, the frame is strong and rigid. The arrangement provides an exceptionally neat and trim appearance since the parts all are enclosed within the hollow framing members. Also, assembly is expedited since the members need merely to be cut to proper length, assembled and locked permanently by denting. In assembled relationship, the internal webs 39 of each of the framing members provide a continuous mounting flange for the screen and glass panels as hereinafter described.

The lower portion of the door is provided with a kick plate or panel 58 directly above the lower framing member 37. This panel rests against the ribs 39 of the lower framing member and against a similar rib formed in an intermediate framing member 60 secured to the vertical framing members 35-35 as shown in Figure 1. To the opposite side of the kick plate 58 is disposed a frame 61 formed of angle members spot welded or otherwise secured to the k1ck plate and frame members, the kick plate being dlsposed between the frame 61 and ribs 39.

As shown in Figure 1, a screen panel 62 is mounted within the storm door with its frame 63 seated against the flange 39 and attached to the flange by screws 64. During the winter season, a glass panel (not shown) may be mounted on the opposite side of the door leaving the screen panel in position; thus, to prepare the door for summer use, the glass panel is simply removed. The details of this structure are not disclosed since they are not essential to an understanding of the present invention.

Having described my invention, I claim:

1. A storm door structure comprising respective hollow metal extrusions providing a rectangular frame consisting of horizontal and vertical hollow framing members, respective corner inserts telescopically engaged within the adjacent end portions of the hollow framing members and joining the same together in angular relationship at the respective corners of the frame, each of said corner inserts having a vertical limb telescopically inserted in the end portion of a vertical framing member and having a horizontal limb extending at right angles to the vertical limb, said vertical framing member having a longitudinal slot formed in the end portion thereof, the vertical framing member having inner walls along opposite sides of the slot, said inner walls confining the vertical limb laterally in the vertical framing member, the horizontal limb of the corner insert extending outwardly through said slot at right angles to the vertical framing member, said horizonal limb having a pair of shoulders formed on opposite sides thereof, said shoulders spaced outwardly from the inner walls and facing said inner walls on opposite sides of the slot, respective wedge members residing on opposite sides of said horizontal limb in parallelism therewith, said wedge members each having respective opposite ends engaged against said shoulders and inner walls, said wedge members having a length providing a force fit between said shoulders and inner walls thereby to frictionally lock the vertical limb of the corner insert in said vertical framing member, said horizontal framing member being telescopically engaged over said horizontal limb and wedge members and retaining said wedge members in position on opposite sides of the said horizontal limb, and means locking the horizontal framing member to said horizontal limb, whereby the respective corner inserts rigidly join the adjacent end portions of the framing members together at the corners of said rectangular frame.

2. A storm door structure comprising respective hollow metal extrusions providing a rectangular frame consisting of horizontal and vertical hollow framing members which are rectangular in cross section, respective corner inserts telescopically engaged within the adjacent end portions of the hollow framing members and joining the same together in angular relationship at the respective corners of the frame, each of said corner inserts having a vertical limb telescopically inserted in the end portion of a vertical framing member and having a horizontal limb extending at right angles to the vertical limb, said vertical framing member having a longitudinal slot formed in the end portion thereof, the framing member having inner walls along opposite sides of the slot, said inner walls confining the vertical limb laterally in the vertical framing member, the horizontal limb of the corner insert extending outwardly through said slot at right angles to the vertical framing member, said horizontal limb having shoulders thereon, said shoulders spaced outwardly from said inner walls and facing said walls, respective wedge members residing on opposite sides of said horizontal limb in parallelism therewith, the wedge members each having respective opposite ends engaged against said shoulders and inner walls on opposite sides of the slot, said wedge members having a length providing a force fit between the shoulders and inner walls, thereby to frictionally lock the vertical limb of the corner insert in said vertical framing member, said wedge members having beveled ends which engage the corners of the rectangular framing member at opposite sides of the inner walls upon assembly, whereby the wedge members at assembly reside in diverging relationship outwardly from the shoulders toward the inner walls and establish a wedging engagement therebetween upon being forced laterally toward one another, the end portion of the said horizontal framing member being telescopically engaged over said horizontal limb and wedge members and retaining said wedge members in position between the abutments and inner walls.

. 3, A corner construction for a storm door or the like having hollow framing members forming a rectangular frame, said corner construction comprising a corner insert for each corner of said frame, each of said corner inserts having a first limb telescopically engaged within an end portion of the first of said hollow framing members, and having a second limb disposed at right angles to the first limb, a second framing member disposed at right angles to the first framing member, said first framing member having a slot in the end portion thereof and having respective inner walls extending along opposite sides of said slot, said inner Walls confining the first limb laterally in the first framing member, the second limb having a neck portion of reduced thickness extending outwardly through said slot at right angles to the first framing member, said neck portion providing a pair of shoulders on opposite sides thereof which are spaced outwardly from the inner walls of the first framing member and facing the same, a pair of wedge members disposed on opposite sides of said neck portion and having opposite ends engaged respectively against the shoulders and against the inner walls of the first framing member on opposite sides of said slot, said wedge members having a length providing a force fit between said shoulders and inner walls thereby to frictionally lock the first limb of the corner insert within said first hollow framing member, the second framing member being telescopically engaged over the second limb and wedge members thereby retaining the wedge members in position on opposite sides of said neck portion.

4. A corner construction for a storm door or the like, having hollow framing members which are rectangular in cross section, said framing members forming a rectangular frame, said corner construction comprising a corner insert for each corner of said frame, each of said corner inserts having a first limb telescopically engaged within an end portion of the first of said hollow framing members, the corner insert having a second limb disposed at right angles to the first limb, a second framing member disposed at right angles to the first framing member, said first framing member having a slot in the end portion thereof and having respective inner walls extending along opposite sides of said slot, said inner walls confining the first limb laterally in the first framing member, the second limb having a neck portion of reduced thickness extending outwardly through said slot at right angles to the first framing member, said neck portion providing a pair of shoulders on opposite sides thereof which are spaced outwardly from the inner walls of the first framing member and facing the same, a pair of wedge members residing on opposite sides of said neck portion in parallelism therewith and having opposite ends engaged respectively against the shoulders and inner walls of the first framing member on opposite sides of said slot, said wedge members having a length providing a force fit between said shoulders and inner walls thereby to frictionally lock the first limb of the corner insert within the first hollow framing member, the length of the wedging members causing the same to reside in diverging relationship at assembly with their respective opposite ends seated against said shoulders and inner walls, thereby to apply endwise pressure relative to the shoulders and inner walls upon being forced toward one another into parallel relationship with said neck portion, the second framing member being inserted telescopically over the second limb and wedge 6 members and retaining the wedge members in parallel relationship with said neck portion.

5. A storm door structure comprising respective hollow metal framing members which are rectangular in cross section, said framing members providing a rectangular frame, respective corner inserts telescopically engaged within adjacent end portions of the hollow framing members, said corner inserts joining said framing members together in right angular relationship at the respective corners of said rectangular frame, each of said corner inserts having a first limb telescopically inserted in the end portion of the first of said hollow framing members, the corner insert having a second limb extending at right angles to the first limb, the first framing member having a slot formed in the end portion thereof, the first framing member having inner walls extending along opposite sides of the slot, the second limb of the corner insert extending outwardly through said slot at right angles to said framing member, said second limb having shoulders on opposite sides thereof, said shoulders being spaced from said first framing member and facing the inner walls on opposite sides of said slot, wedge members residing on opposite sides of said second limb in parallelism therewith, said wedge members having respective opposite ends engaged against said shoulders and inner walls, said wedge members having a length providing a force fit between the shoulders and inner walls, thereby to frictionally lock the first limb of the corner insert in said first hollow framing member, and a second framing member disposed at right angles to the first framing member and having an end portion telescopically engaged over the second limb and said wedge members and retaining the wedge members in parallelism on opposite sides of the first limb of the corner insert.

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